Piston Type Axial Expander

ABSTRACT

The invention relates to a piston type axial expander ( 4 ) comprising:
         an intake cylinder head ( 10 ) for vapor under pressure comprising a vapor intake opening ( 100 ),   an expansion zone comprising a plurality of cylinders ( 110 ), wherein a piston ( 111 ) sliding in each respective cylinder is connected to a shaft ( 40 ) by an inclined plate ( 20 ), each piston being parallel to said shaft.   a plurality of poppet valves ( 12 ) arranged orthogonally to the shaft ( 40 ) in the intake cylinder head ( 10 ) allowing alternating intake of vapor into said cylinders ( 110 ), each valve ( 12 ) being controlled by a cam ( 21 ) arranged on the shaft ( 40 ),   a lift mechanism ( 13 ) for each valve cooperating with the cam,   a return mechanism for each valve.       

     The intake cylinder head ( 10 ) comprises:
         an enclosed and lubricated central zone ( 10 A) comprising the cam and the lift and return mechanisms of the valves,   a peripheral zone ( 10 B) in which the intake opening ( 100 ) leads, extending around the central zone ( 10 A).

FIELD OF THE INVENTION

The present invention relates to a piston type axial expander.

BACKGROUND OF THE INVENTION

Systems for converting heat coming from an engine into mechanical energy are known. Such assemblies are known in particular for converting heat emitted by internal combustion engines, which is dissipated in particular during the expulsion of exhaust gases and is therefore lost.

Such assemblies are subjected to demanding weight and size requirements. They thus tend to become more and more compact.

These systems operate with a working fluid that is subjected to a Rankine thermodynamic cycle comprising compression, evaporation possibly supplemented with superheating, expansion in an expander and condensation. The expansion within the expander makes it possible to actuate movable members such as pistons so as to obtain mechanical energy.

Of particular interest are systems comprising an expander which includes an intake cylinder head for vapor under pressure, comprising an intake opening for the vapor and an expansion zone comprising a plurality of cylinders, wherein a piston sliding in each respective cylinder is connected to a shaft by an inclined plate, each piston being parallel to said shaft.

A plurality of valves arranged in the intake cylinder head make possible the alternating intake of vapor into said cylinders, each valve being controlled by a cam arranged on the shaft and cooperating with a lift and return mechanism of each valve.

In this type of expander, the pistons can be single-acting, that is having mechanical work occur by expansion of the vapor only on one side, or double-acting, that is having mechanical work occur by expansion of the vapor on both of its sides.

Document WO 2005/073511 describes, with reference to FIGS. 1 and 6, expanders comprising single-acting pistons. In these expanders, the connection between the valve stem and the cam is lubricated because it is located in a crankcase also containing the inclined plate. However, this configuration has the drawback of requiring very long valve stems, which increases their mass and consequently inertia loads. The return mechanism of the valves—generally a spring—must therefore be sized correspondingly, which further increases the mass and the size of the expander. Moreover, this construction of the valves is hardly compatible with the use of double-acting pistons. Indeed, in the case of FIG. 1, the shaft would interfere with the valves and, to avoid passage of lubricant into the cylinder head containing high pressure vapor, it would be necessary to provide special seals, which are expensive and not very reliable at the operating temperatures of the expander. In the case of FIG. 6, the positioning of the valves at the periphery of the expander is more favorable to the use of double-acting pistons, but would require an increase of the outer diameter of the expander.

Document U.S. Pat. No. 4,262,579 describes another piston type axial expander. This document does not show any confining of the zone extending from the cam to the cylinder in which each piston slides. Consequently, any leakage of vapor through the guides of the valve stems is lost. Furthermore, the intake angles of the vapor expanders are generally very small, which requires extremely stiff valve lifts and requires, for expanders rotating at high speed, extremely stiff valve return springs. These springs being bulky, particularly in the axial direction, they penalize the compactness of the expander.

However, in applications intending to carry such a conversion system on a vehicle, it is necessary to minimize the size and the mass of the different components of the system.

BRIEF DESCRIPTION OF THE INVENTION

One aim of the invention is to correct the disadvantages of existing expanders and to design a piston type axial expander which is more compact while still affording good lubrication and making it possible to avoid vapor losses caused by possible leaks.

In conformity with the invention, a piston type axial expander is proposed comprising:

-   -   an intake cylinder head for vapor under pressure comprising a         vapor intake opening,     -   an expansion zone comprising a plurality of cylinders, wherein a         piston sliding in each respective cylinder is connected to a         shaft by an inclined plate, each piston being parallel to said         shaft,     -   a plurality of poppet valves arranged orthogonally to the shaft         in the intake cylinder head alternating intake of vapor into         said cylinders, each valve being controlled by a cam arranged on         the shaft,     -   a lift mechanism for each valve cooperating with the cam,     -   a return mechanism for each valve,         said expander being characterized in that the intake cylinder         head comprises:     -   an enclosed and lubricated central zone comprising the cam and         the lift and return mechanisms of the valves,     -   a peripheral zone in which the intake opening leads, extending         around the central zone.

“Upper” or “lower” means a relative position with respect to the position of the expander during its normal use.

“Longitudinal” means a direction parallel to the axis of the shaft.

The terms “central” and “peripheral” are defined relative to the shaft axis: the central zone including said shaft axis and the peripheral region surrounding at least part of the central zone.

In a particularly advantageous manner, said peripheral region extends only around an upper portion of the central zone.

Preferably, said peripheral zone does not comprise a common wall with the lower portion of the central zone.

According to one embodiment, the expander further comprises a lubrication circuit for the central zone, said circuit comprising:

-   -   a channel arranged in the shaft and leading into the central         zone through a lubricant entry opening, and     -   a lubricant output opening arranged in a wall of the lower         portion of the central zone.

Moreover, the central zone advantageously comprises, in its upper portion, a through opening for the vapor in fluid connection with an exhaust zone of the expander.

According to a preferred embodiment, the return mechanism of each valve comprises a torsion bar and a return rocker arm extending between said torsion bar and the stem of a respective valve so as to exert a force pressing the head of the valve into the seat of said valve.

Preferably, the torsion bar is parallel to the shaft.

According to one advantageous embodiment, the return rocker arm is secured to the valve stem by a fork.

Preferably, said fork is in contact with the valve tip at two contact points of which the axis is not parallel to the axis of rotation of the return rocker arm, so that the fork induces a rotation of the stem about the axis of said stem.

Moreover, the lift mechanism for each valve comprises a pivoting rocker arm secured to a respective valve, said rocker arm, so-called a cam follower rocker arm, cooperating with the cam so as to separate the head of said valve from the seat of said valve.

According to one embodiment, the pistons are double-acting.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and advantages will be revealed by the detailed description which will follow, with reference to the appended drawings wherein:

FIG. 1 is an schematic diagram of a Rankine circuit,

FIG. 2 is a perspective view of the outside of an expander according to one embodiment of the invention,

FIG. 3 is a cross-section view at the cylinder head of the expander of FIG. 2,

FIG. 4 is a longitudinal section view of the expander of FIG. 2,

FIGS. 5 and 6 are perspective view of lift and return mechanisms of a valve according to one embodiment of the invention,

FIG. 7 is a perspective view of a particular embodiment of the return rocker arm,

FIG. 8 is a cross-section view at the cylinder head of an expander according to another embodiment of the invention,

FIG. 9 is a cross-section view at the cylinder head of the expander according to one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a circuit implementing a Rankine thermodynamic cycle.

Shown in this figure is a circuit 1 containing a working fluid, the circuit 1 comprising:

-   -   a pump 2, typically a pump designed to deliver a flow of working         fluid which establishes a pressure of 40 bars on its discharge;     -   a first heat exchanger 3 which is called hereafter an         “evaporator;”     -   an expander 4;     -   a second heat exchanger 5, which will hereafter be called a         “condenser;”     -   a bypass device 6.

The pump 2 supplies the evaporator 3 with working fluid in the liquid state under pressure, typically on the order of 40 bars.

The evaporator 3 is located in a medium with elevated temperatures, and thus accomplishes heat transfer between this high-temperature medium and the working fluid so that the latter is evaporated and passes into the gaseous state.

The working fluid leaving the evaporator 3 is therefore in the gaseous state and under pressure.

The working fluid then passes through the expander 4, wherein expansion occurs.

The expansion of the working fluid in the expander 4 involves movable means such as a rotating mechanical shaft, thus allowing the energy of the working fluid to be recovered.

The movable means are advantageously coupled to the shaft of the internal combustion engine, so as to re-inject a mechanical torque. The movable means can also be coupled to energy conversion means such as an electric generator, so as to allow conversion of the energy resulting from the expansion into electrical energy.

The working fluid leaving the expander 4 is therefore in the gaseous state and at a low pressure, typically on the order of 2.2 bars.

The working fluid then passes through the condenser 5, which is located in a medium having a low temperature so as to accomplish heat exchange between the working fluid and this low-temperature medium to reduce the working fluid temperature, and bring it back to the liquid state.

The working fluid leaving the condenser 5 is therefore in the liquid state and at low pressure, on the order of 2.2 bars. It is then re-injected into the circuit 1 by the pump 2 and repeats the cycle previously described.

The circuit 1 shown further comprises a bypass device 6 designed to make it possible to take all or a portion of the working fluid upstream of the expander 4 and re-inject it into the circuit 1 downstream of the expander 4, thus functioning as a short-circuit of the expander 4. Such a device is often called a “bypass.”

Such a bypass device 6 is advantageously used in the initiation phase of the circuit 1 so as to allow the establishment of conditions of temperature and pressure in the circuit 1 and/or so as to achieve a temperature rise in the crankcase 17, or in the event of needing to modulate the operation of the circuit 1.

FIG. 2 is a perspective view of the outside of an expander according to an embodiment of the invention.

In this embodiment, the expander contains double-acting pistons, vapor under pressure being received in two cylinder heads 10 located on either side of the expander. Although it is preferred, this configuration is not limiting and construction with single-acting pistons can be implemented without departing from the scope of the present invention.

The expander 4 comprises an intake opening 100 for vapor under pressure in each cylinder head 10, as well as two exhaust openings 200.

FIG. 3 is a cross-section view at the cylinder head of the expander of FIG. 2, in its normal utilization position. FIG. 4 is a longitudinal section view of said expander.

The cylinder head 10 has an intake opening 100 for vapor under pressure.

The cylinder head also comprises a central zone 10A and a peripheral zone 10B. For reasons explained in more detail below, the peripheral zone 10B partially surrounds the central zone 10A. More precisely, the peripheral zone 10B extends only around the upper portion of the central zone 10A.

The opening 100 leads into the peripheral zone 10B of the cylinder head.

The expander 4 comprises cylinders 110 (three in number on each side of the expander of FIG. 4) which are arranged in an expansion zone, within which a respective piston 111 slides (see FIG. 4). As indicated above, in this figure the pistons are double-acting, although this configuration is not limiting.

Each piston 111 is connected to a shaft 40 by an inclined plate 20, (see FIG. 4), each piston being parallel to the shaft 40. In the normal utilization position, the shaft 40 extends in a substantially horizontal plane. The plate is arranged in a crankcase 14 containing a lubricant which is in the liquid state under the operating conditions of the expander. The connection between each piston and the inclined plate is therefore lubricated.

Each cylinder is in fluid connection with an exhaust zone which leads from the expander through an exhaust opening 200, for exhausting the working fluid in the expanded state.

In a region extending into the cylinder head 10, the shaft 40 carries a cam 21. Said cam can form an integral part of the shaft or be manufactured separately from the shaft and then rigidly secured to it.

Said cam 21 controls a plurality of valves 12 (three in the embodiment of FIG. 3, this number being purely indicative) so as to allow intake, from the peripheral zone 10B, of vapor under pressure into a respective cylinder 110.

The valves 12 are poppet valves. In a manner known per se, such valves comprise:

-   -   a circular head 120, performing the functions of a closure         member between the intake cylinder head and each cylinder. When         the valve is in the closed position, it will press against a         seat of valve 101 arranged in the cylinder head to ensure         sealing of the cylinder;     -   a cylindrical stem 121 the diameter whereof is substantially         less than that of the head, which provides for vertical guidance         of the valve by sliding in a valve guide 102 provided in the         cylinder head;     -   a collar 122 connecting the head 120 to the stem 121 with a high         radius of curvature,     -   a tip 123 located at the end of the stem opposite the head,         coupled to the lift mechanism 13 of the valve which cooperates         with the cam 21.

The poppet valves are arranged in a plane substantially orthogonal to the axis of the shaft.

One advantage of poppet valves is that they are of small size, which makes it possible to minimize inertia loads, thus favoring the compactness of the expander. Moreover, poppet valves are an intake system that requires good lubrication only in the contact between the stem and the guide. The contact between the head and the seat, which is the hottest contact of this mechanism, can content itself with low lubrication, for example a deposition of lubricant circulating with the working fluid of the expander. Mass proportions of lubricant in the working fluid less than or equal to 5% are sufficient.

As can be seen in FIG. 3, the cam and the lift and return mechanisms of the valves are located in the central zone 10A of the cylinder head.

This zone 10A is enclosed and lubricated, which ensures good operation of the mechanical connections involved while still avoiding losses of vapor in the event that leaks occur at the valve guides.

Indeed, the zone 10A advantageously comprises a discharge hole 103 for such possible vapor leaks toward the exhaust zone of the cylinders. Thus, the vapor is re-injected into the vapor circuit.

Moreover, the lubricant is brought into the central zone 10A from the crankcase by means of a bore 22 made in the shaft 40. Said bore extends longitudinally inside the shaft 40 and leads by a radial bore 23 into the zone 10A.

To this end, the lubricant is pumped from the crankcase 14 through channels 150 by an oil pump 15 located at one end of the shaft 40.

The lubricant thus introduced into the central zone 10A makes it possible to lubricate the different mechanical connections, then it falls by gravity into the lower portion of said zone 10A.

The central zone 10A also comprises a lubricant output opening 104 arranged in a wall of the lower portion of said zone. Said opening is in fluid connection with the crankcase 14, so as to allow return of the lubricant to the crankcase.

Inasmuch as the lower portion of the central zone 10A does not have a common wall with the peripheral zone 10B which is subjected to a high temperature, the lubricant is not uselessly heated prior to its discharge from the central zone 10A, which prevents it from being degraded.

Moreover, the oil pump 15 being located at the end of the expander, ducts can thus be provided in the lower portion of the central zone for feeding the oil pump with lubricant from the crankcase and for feeding, from the oil pump, certain zones of the expander. Thus, ducts (not shown) can also be provided in this lower portion for discharge of the lubricant feeding the rotating seal of the shaft.

In the embodiment illustrated in FIGS. 2 to 4, the pistons are double-acting and the expander comprises two intake cylinder heads 10 on either side of the expander. The longitudinal bore 22 made in the shaft makes it possible to supply lubricant to the central zone of each of both intake cylinder heads.

Alternatively or as a supplement, a duct 103 can be provided between the exhaust zone of one or more cylinders and the central zone 10A so as to allow flow of the exhaust vapor after expansion toward the central zone 10A. This configuration allows, in the case where the working fluid is loaded with lubricant, to lubricate the mechanical connections involved in controlling the valves using the lubricant present in the vapor, alone or as a supplement to the lubrication coming from the shaft.

A preferred embodiment of the valve lift and return mechanisms will now be described in more detail, with reference to FIGS. 5 and 6.

The lift mechanism for a valve comprises a rocker arm 130, so-called a “cam follower rocker arm” pivoting about an axis parallel to the shaft and having a zone 131 in contact with the cam. Said rocker arm is coupled, through a zone opposite to the zone 131, with the tip 123 of the valve 12 so as to exert a thrust on the valve when the zone 131 is cooperating with the cam 21. This thrust has the effect of separating the head 120 of the valve from its seat 101, thus allowing vapor to be received in the corresponding cylinder.

The expander further comprises return means for the valve making it possible to exert a force to press the head of the valve against its seat.

In the embodiment illustrated in FIGS. 5 and 6, this return means comprises a torsion bar 132 arranged longitudinally in the expander. At one of its ends, the torsion bar is rigidly secured to a rocker arm 133, so-called a “return rocker arm.” At its opposite end, the torsion bar is rigidly secured to a tube 134, inside which it is arranged. Said tube 134 is itself fixed to the cylinder head. Lifting the valve slightly twists the bar 132, this torsion inducing in the bar a returning moment.

The return rocker arm 133 is secured to the stem 121 of the valve in the vicinity of the tip. The connection between the return rocker arm 133 and the stem 121 is made by a fork 1330 extending to the end of the return rocker arm opposite the torsion bar. The fork 1330 has two parallel arms surrounding the stem 121, the distance between the arms being equal to the diameter of the stem.

The speed of rotation of the cam is in fact high and the opening angle of the valve is very small. Thus the movement of the valve engenders extremely high inertia loads. The mass of the valve must therefore be reduced and inertia must be opposed with a considerable return force. But it is not possible with a compact spring to have sufficient return force for the small lift heights used, without imposing a large spring preload. This preload causes the cam follower rocker arm to rub constantly on said cam, which increases friction in the motor as well as wear. A torsion bar makes it possible to have high stiffness, which makes it possible to avoid the use of a considerable preload.

Whatever the means of implementing the torsion bar, this return mechanism is particularly advantageous in that it has great compactness. In fact, with equal stiffness, the torsion bar has smaller dimensions than a coil spring used conventionally as a return means.

FIG. 7 is a perspective view of an advantageous embodiment of the return rocker arm, said rocker arm 133 being suitable for use in the return mechanisms shown in FIGS. 5 and 6.

Contacts C1, C2 between the arms of the fork 1330 and the tip 123 of the valve allow rotation of the stem about its axis. This rotation is induced by a low angle α provided between the axis X of rotation of the return rocker arm and the axis X′ of the contact points C1, C2 of the fork, which generate a different force at each of both contacts. This makes it possible to permanently fit the head of the valve on its seat and thus to limit leaks throughout the life of the expander.

FIG. 8 is a cross-section view at the cylinder head of another embodiment of the axial expander according to the invention. Reference symbols identical with those of the preceding figures designate elements having the same functions as in the previous embodiment, and which are therefore not described again.

In this embodiment, the return function is not carried out by torsion bars but by springs 140 each arranged between a valve guide and the tip of the respective valve. The springs 140 thus exert a return force on the valve aiming to press it against its seat.

This embodiment is however less preferred, because the springs 140 must be very stiff and consequently bulky, which penalizes the compactness of the expander.

Moreover, the control laws for lifting the valves are very stiff because each valve is open only over a very narrow angular range (of the order of 70-80°) compared with an internal combustion engine. The lift height of the valves is also small (of the order of 2 mm) with respect to an internal combustion engine. If the lifting speed is too high, the valve is catapulted out of its seat and its inertia makes it difficult for the return mechanism to maintain contact with the cam or, if applicable, on the cam follower rocker arm as in FIG. 8. In this case (called “valve floating”) the duration of opening of the valve is no longer controlled (ballistic operation) and shocks when contact is resumed lead to long-term failure of the system.

In the embodiment of FIG. 9, the pistons are double-acting and the expander comprises two intake cylinder heads 10 on either side of the expander. Each cylinder head 10 has three intake openings 100 a, 100 b and 100 c for vapor under pressure. Each cylinder head also comprises a central zone 10A and a peripheral zone 10B in which the intake openings 100 a, 100 b and 100 c lead. This embodiment is particularly advantageous in that it limits the size of the cylinder heads and thus their mass and cost.

Finally, it goes without saying that the examples that have just been given are only particular illustrations which are never limiting as regards the field of application of the invention.

REFERENCES

-   WO 2005/073511 -   U.S. Pat. No. 4,262,579 

1. A piston type axial expander comprising: an intake cylinder head for vapor under pressure comprising a vapor intake opening), an expansion zone comprising a plurality of cylinders, wherein a piston sliding in each respective cylinder is connected to a shaft by an inclined plate, each piston being parallel to said shaft, a plurality of poppet valves arranged orthogonally to the shaft in the intake cylinder head allowing alternating intake of vapor into said cylinders, each valve being controlled by a cam arranged on the shaft, a lift mechanism for each valve cooperating with the cam, a return mechanism for each valve, wherein the intake cylinder head further comprises: an enclosed and lubricated central zone comprising the cam and the lift and return mechanisms of the valves, a peripheral zone in which the intake opening leads, extending around the central zone.
 2. The expander according to claim 1, wherein said peripheral zone extends only around an upper portion of the central zone.
 3. The expander according to claim 2, wherein said peripheral zone does not comprise a common wall with the lower portion of the central zone.
 4. The expander according to claim 1, further comprising a lubrication circuit for the central zone, said circuit comprising: a channel arranged in the shaft and leading into the central zone through a lubricant entry opening, and a lubricant output opening arranged in a wall of the lower portion of the central zone.
 5. The expander according to claim 1, wherein the central zone comprises, in an upper portion thereof, a through opening for the vapor in fluid connection with an exhaust zone of the expander.
 6. The expander according to claim 1, wherein the return mechanism of each valve comprises a torsion bar and a return rocker arm extending between said torsion bar and the stem of a respective valve so as to exert a force pressing the head of the valve into the seat of said valve.
 7. The expander according to claim 6, wherein the torsion bar is parallel to the shaft.
 8. The expander according to claim 6, wherein said return rocker arm is secured to the valve stem by a fork.
 9. The expander according to claim 8, wherein the fork is in contact with the valve tip at two contact points of which the axis is not parallel to the axis of rotation of the return rocker arm, so that the fork induces a rotation of the stem about the axis of said stem.
 10. The expander according to claim 1, wherein the lift mechanism of each valve comprises a pivoting cam follower rocker arm secured to a respective valve, said cam follower rocker arm cooperating with the cam so as to separate the head of said valve from the seat of said valve.
 11. The expander according to claim 1, wherein the pistons are double-acting. 